ZETA MAGNETIC AGITATORS For sterile liquid processing www.zeta.com
ZETA AGITATORS A VERSATILE PRODUCT FAMILY Proven agitator technology that meets the highest standards of sterile design and reliability. An overview of our product range: ZETA system with top-mounted agitator AMRe Bioreactors for bacteria and cell culture PRODUCT GROUP PRODUCT TYPE SERIES APPLICATIONS TORQUE RANGE Process tanks upstream and downstream of fermentation vessels Processes with carrier suspensions Vaccine production Solutions for injection and infusion Fractionation of blood plasma Bottommounted Magnetic impeller with improved run-dry capability BMRT Hygienic and sterile process tanks in pharmaceutical and food/beverage production, up to approx. 60.000 litres Bioreactor BMRF In bioreactors for bacteria and cell cultures; applicationspecific multiple-impeller design 50-30.000 Ncm 50-30.000 Ncm Manufacturing of active ingredients Fine chemicals Food and beverage, including dairy brewing fruit juice fruit preparations Special applications, for example high-pressure reactors cooling media Top-mounted Container Externally mounted coupling Internally mounted coupling Magnetic coupling on inside of vessel AMRe AMRi CMRT In bioreactors for cell cultures; application-specific multiple-impeller design Smaller bioreactors and process tanks; applicationspecific multiple-impeller design Top-mounted agitator for the food industry 300-2.500 Ncm 30-550 Ncm 30-2.500 Ncm Fermenter agitator BMRF 2 Evolution of Technology www.zeta.com 3
ZETA MAGNETIC AGITATORS FULLY SEALED, RELIABLE AND PERFECTLY CLEANABLE ZETA are the product of many years of experience with sterile design and process engineering. ZETA MAGNETIC IMPELLERS The standard impeller type, suitable for many applications. Magnetic agitator types Bottom-mounted agitator The big advantage of ZETA is the complete separation of the interior of the tank from the outside. In contrast to conventional, there is no shaft penetrating the tank and therefore no mechanical seal. This eliminates the risks of leaks and microbial contamination and the need for special maintenance that are associated with conventional. We have developed our with special emphasis on optimising their cleanability, which is essential for sterile processes. Independent tests, e.g. EHEDG, confirm that these can be qualified for such applications. Wide product range: We offer a variety of types of bottom-mounted and top-mounted. Bottom-mounted are state of the art for low-viscosity liquids in pharmaceutical and biotechnology production. The compact design, low maintenance and high reliability guarantee trouble-free production. Using a bottom-mounted agitator also frees up space on the tank lid for sensors, valves and sight glasses. BMRT rotor design outer bearing inner bearing containment shell retaining bolt Open design flow through the bearing gap vertical blade outer rotor BMRT: open design & optimal flow through rotor Open design with excellent cleaning: hub and rotor are connected only by the impeller blades. The ceramic bearings are oversized (in diameter and height), product-lubricated and consist of outer (silicon carbide) and inner (zirconium oxide) bearing. This results in exceptional stability, good emergency running properties and particle generation below detectable levels. Ease of maintenance ceramic bearing parts can be replaced by users on site; no spare rotor needed. A very large gap between the rotor and the containment shell maximizes flow through the gap and minimizes shear stress (see picture Open design flow through the bearing gap) CFD-engineered mixing: fluid is drawn from above and pumped radially. Perfect for mixing solid powders into liquids; rapid breakdown of temperature and concentration gradients, ensures good heating and cooling. Agitators for special applications: BMRT impellers: As well as our standard range of, we also make customized versions to order. Features including the dimensions of the impeller, rotational speed or the type of impeller can be modified to perform customer-specific mixing tasks. With monitoring of the liquid level and rotational speed, and using a type-approved motor, the can be used for vessels in ATEX zones 0 or 1 according to the directive 2014/34/EU. Impeller and installation options New and stronger materials enable us to reach a higher transferable torque for the same geometry of the drive and rotor. ZETA offers a wide range of drive sizes with operating torques from 30 Ncm to 300 Nm to suit every specific application. BMRT impellers ensure that the optimal formulation of the product is achieved throughout the whole volume. When the product is being transferred out of the vessel, the homogeneity of the mixed product is maintained reliably down to the last drop. The open design enables easy cleaning (CIP) and sterilization (SIP). ZETA experts will help you select the best impeller variant for your process, the best drive unit and the most suitable installation option (welded or Plug In containment shell). Option: drive unit in stainless steel 4 Evolution of Technology www.zeta.com 5
DESIGN FEATURES & FUNCTIONS OF BOTTOM-MOUNTED MAGNETIC AGITATORS Reliable and easy to maintain Large catalogue of agitator models and alternative technical solutions One example of a rotating SiC bearing Bearings Extra large Plug In flange Zirconium oxide inner bearing: less risk of breakage, resistant to damage by sudden settling of the rotor Silicon carbide outer bearing: with channels in the face side (see picture) for better lubrication of the bottom contact surface and enhanced cleaning (CIP) Run-dry capability with the rotor type BMRT: Magnetic lifting of the impeller reduces the load on the bearing surface so that the agitator can be kept running while the vessel is emptied (mixing down to the last drop). Lowering Device: The Plug In flange is also available with a large-diameter flange which allows the whole agitator head to be extracted from the vessel through the bottom opening. Impeller speed monitoring: Sometimes a problem inside the tank or an operating error can lead to forces on the agitator head that exceed the maximum transmissible torque, so that the coupling decouples. In this situation the agitator head stops turning although the drive is still running. To control this issue, we offer an optional contactfree rpm sensor for the agitator head. BMR with large Plug In flange speed sensor position: lowered driving magnets lowering device position: driving magnets during operation Agitators of the size 2.500 (25 Nm) and upwards are supplied with a special lowering mechanism that withdraws the drive magnet out of the containment shell. Benefits of the retractable drive magnet: Controlled removal and safe insertion of the impeller due to withdrawal of the drive magnet. The drive unit remains in position while the drive rotor is lowered out of the containment shell. Avoids damage to the ceramic bearings. Improved safety: The device protects against the crushing hazard involved in placing the agitator head on the bearing, and thus meets the demand of the EC Machinery Directive for designed protection against injury. Removable containment shell (Plug In): For safety reasons, the speed sensor is included as standard in for use in ATEX Zone 0 (directive 2014/34/EU). Attachment of the drive shell by TriClamp: Attaching the drive with a TriClamp fitting enables it to be removed quickly without tools, for example when using the agitator with an autoclavable tank. As another alternative, bayonet fittings are also possible. Extractor tool: An optional tool for the removable containment shell (Plug In). The tool enables the containment shell to be removed from the tank easily and gently. Impeller rpm monitoring TriClamp Attachment As an alternative to a version with a flange for welding into the vessel, the agitator can be supplied with a removable containment shell. This can facilitate maintenance. This practical Plug In solution is becoming more popular and makes it easier to switch from shaftdriven with mechanical seals to. containment shell Plug In and weld-in containment shells Electropolishing of stainless steel surfaces ZETA has an electropolishing unit in-house so that we can meet the growing demand for the highest possible surface quality. Extractor Tool 6 Evolution of Technology www.zeta.com 7
INNOVATIVE SOLUTIONS FOR OUR CUSTOMERS EVOLUTION OF TECHNOLOGY Customised Systems Engineering & Services Automation Products & Components Food Systems ZETA Business Activities Bioreactors & Fermentation Systems Downstream Systems Preparation Systems CIP/SIP Systems Magnetic Agitators Freeze & Thaw Systems Engineering Automation Customer Benefits Deep process understanding GMP FDA Compliance Super-Skid Design Focus on Sterility High Process Reliability Scale-up capabilities Experience in complex biologics Customized Process Systems ZETA Biopharma Zetaplatz 1, 8501 Lieboch/Graz, AUSTRIA Phone: + 43 3136 90 100, E-Mail: info@zeta.com www.zeta.com